Continuous washing method

ABSTRACT

Method and apparatus for loosening soil from a mass of pervious cloth in which wash solution is applied to the rolls in the form of a plurality of reciprocable cascades to maintain the surfaces of the pervious cloth wet for a time sufficient to saturate the same; excess wash solution is continually drained from the mass of tightly-wound rolls.

United States Patent [191 Bahnsen Oct. 16, 1973 [54] CONTINUOUS WASHING METHOD 1,906,492 5/1933 Spindler 68/205 R X Inventor: Erwin B. Bahnsen, Hinsdale, In 1,516,593 11/1924 Eyrich 68/205 R X [73] A St A C r FOREIGN PATENTS OR APPLICATIONS ssigneez einer merican orpora ion,

s t L e City, Utah 674,841 11/1963 Canada 68/205 R 1 Filedl p 1971 PrimaryExaminer-William 1. Price [211 App]. NOJ 184,576 Attorney-Prangley, Dithmar, Vogel, Sandler &

Stotland Related U.S. Appl cation Data [62] Ser. No. 879,764, Nov. 25, 1969, Pat. No. ABSTRACT Method and apparatus for loosening soil from a mass [52] U.S. C1. 8/154 of pervious cloth in which wash solution is applied to [51] Int. Cl. 1505c 5/00 the rolls in the form of a plurality of reciprocable cas- [58] Field of Search 8/151, 152, 154, cades to maintain the surfaces of the pervious cloth 8/155, 155.1, 155.2, 158; 68/205 R, 177, wet for a time sufficient to saturate the same; excess 178, wash solution is continually drained from the mass of tightly-wound rolls. [56] References Cited UNITED STATES PATENTS 7519195 Pew i s???" 899,339 9/1908 Shuman 68/205 R X 2 45 /5 2/45 I /5 245 245 102 102 v .r' \k 3 76 I I I 2 f -375 I #676 e y5 ooossszoooo soaiwscswcontinua PATENTEDUCT 15 I975 SREEI 03 0F 10 Saw WNW

PATfNIfDunnsms 3.765838 sum as or 10 PATENTEDUET 1s ms SREU 0BUF1O IN Wm PATENTEDUET 16 :975 3765838 sum 10? or 10 PATENTEUUU 16 ms SHEET 09 0F 10 QQW PATENTEDHBI 16 I973 SHEET 10 N 10 FIG.

CONTINUOUS WASHING METHOD This is a division of application Ser. No. 879,764, filed Nov. 25, 1969 now U.S. Pat. No. 3,698,214.

The present invention relates to methods for the industrial processing of soiled fabric articles and more specifically to a method for loosening soil from a mass of randomly arranged, tightly wound multi-layer rolls of pervious cloth by saturating each of the rolls to the innermost layer thereof with a wash solution.

It is an object of the present invention to provide a method for loosening soil from a mass of pervious cloth comprising transporting the mass of pervious cloth on a foraminous conveyor through a crib surrounding the conveyor and applying a wash solution to' the mass of tightly wound rolls to maintain the surfaces thereof wet for a time sufficient to. saturate each of the tightly wound rolls to the innermost layer thereof, while continually draining excess wash solution from the mass of tightly wound rolls through the foraminous conveyor whereby to loosen the soil from the cloth.

It is another object of the present invention to provide a method of the type set forth in which the wash solution is applied to the mass of pervious cloth as a cascade, the cascade being reciprocable along a predetermined path overlying the conveyor.

It is a further object of the present invention to provide a method of the type set forth in which the drained wash solution is collected and make-up wash solution is added to the collected wash solution and recirculated to the cascade of wash solution.

It is a still further object of the present invention to provide a method of the type set forth in which a plurality of reciprocable cascades of wash solution are provided, the plurality of cascades defining a corresponding number of zones through which the mass of pervious cloth is transported.

It is another object of the present invention to provide a method of the type set forth in which the temperature of the cascades of wash solution applied to the mass of pervious cloth is controlled thereby to produce a thermal shock therein.

The invention, both as to its organization and method of operation, together with further objects and advantages thereof, will best be understood by reference to the following specification taken in connection with the accompanying drawings in which:

FIG. 1 is a diagrammatic illustration with certain portions in section of a four-zone apparatus embodying the present invention for applying wash solution to the mass of randomly arranged, tightly wound, multi-layer rolls of pervious cloth to saturate each of the tightly wound rolls to the innermost layer thereof, whereby to loosen the soil therefrom;

FIGS. 2 to 4 are diagrammatic views of the apparatus shown in FIG. 1 to more fully illustrate the variable capacity thereof;

FIG. 5 is a side elevational view of the apparatus shown in FIG. 1 and fiirther showing the position of the wash solution supply mechanisms defining the four zones, the heaters therefor and the apparatus for adding make-up solution thereto;

FIG. 6 is a plan view of the apparatus shown in FIG.

FIG. 7 is an enlarged side elevational view partly broken away of a portion of the apparatus shown in FIG.

FIG. 8 is an enlarged view of a portion of the conveyor shown in FIG. 1;

FIG. 9 is a view partly in section of a portion of the conveyor shown in FIG. 8 taken along line 99;

FIG. 10 is an enlarged side elevational view of a portion of the apparatus shown in FIG. 5;

FIG. 11 is a sectional view of the apparatus shown in FIG. 10 taken along line 11-1 1 and particularly showing the position of the drive for the wash solution supply mechanism and the spatial relationship of the endless conveyor belt;

FIG. 12 is a sectional view of the apparatus shown in FIG. 11 taken along line 12-l2;

FIG. 13 is an enlarged view partly in section of the first mixing stage shown in FIG. 5 and showing the spatial relationship between the mixing chamber, the additive supplies and the reservoir;

FIG. 14 is a view partly in section of the supply mechanism for applying wash solution to the mass of tightly wound rolls and the drive mechanism for providing reciprocal movement thereto;

FIG. 15 is a side elevational view partly broken away and partly in section of the mechanism shown in FIG. 14 taken along line 1515 and particularly showing how wash solution is supplied thereto;

FIG. 16 is a plan view of the supply mechanism shown in FIG. 14;

FIG. 17 is an elevational view of a sectional supply mechanism for applying wash solution to the mass of tightly wound rolls without the drive mechanism shown in FIG. 15-, and

FIG. 18 is a sectional view particularly showing the trough of the mechanism shown in FIG. 17 taken along line 1818.

As shown in the drawings, and particularly in FIGS. 1, 5 to 7, and 10 to 12, there is provided a soilloosening apparatus including a crib 106 for retaining the mass 102 of tightly wound rolls 101, the crib 106 having two elongated spaced-apart upstanding side walls 107 and a top wall 109 extending thereover, the top wall 109 being corrugated and having raised portions 110, the portions 110 extending generally horizontally, lower portions 111, ,the lower portions 111 being vertically spaced from the raised portions 110 and also extending generally horizontally and parallel to the raised portions 110 and connecting portions 1 12, the connecting portions 112 interconnecting the raised portions 110 and the lower portions 111. The crib 106 is also provided at spaced-apart intervals with cross-ties 113 for increasing strength and rigidity of the crib 106, the cross-ties 113 being tubular in shapeand extending transverse to the longitudinal axis of the crib 106, the cross-ties 113 also providing support with angle brackets 114 for the top wall 109.

The crib 106 also includes at spaced-apart points along the side walls 107 corresponding to the positions of the cross-ties 113 a plurality of support columns 1 15, the support columns 115 being positioned exterior to each side wall 107 and each column 115 being aligned in a plane transverse to the longitudinal axis of the crib 106 with another column 115, the columns being connected to the walls 106 as hereinafter explained. The columns 115 are identical and therefore only one will be described in detail, the column includes a rectangular post 1 16 supported by a pair of L-shaped plates 1 17, the plates 117 being spaced apart and suitably secured to each side of the post 116 such as by welding. The L- shaped plates 117 have a vertical abutment surface 118 on the vertical part of the L, an upper abutment surface 119 on the horizontal part of the L and a lower abutment surface 120 also on the horizontal part of the L. As seen from the drawings, the support columns 115 are placed at evenly spaced-apart points along the crib 106, at each point two columns 115 are provided along a plane normal to the longitudinal axis of the crib 106 for a purpose to be hereinafter explained, it being realized that this is but the preferred embodiment of the invention, other support arrangements being considered within the scope of the present invention.

Each of the support columns 1 rests on a sole plate 125, the sole plates 125 extending parallel to the longitudinal axis of the crib 106 and being spaced apart a distance equal to the distance between opposed support columns 115. Each of the sole plates 125 is in the form of an l-beam having an upper horizontal flange 126 and a lower horizontal flange 127 interconnected by a vertically extending bight 128, the upper flange 126 having an abutment surface 129- thereon providing support for the lower abutment surfaces 120 on the bottom of the two L-shaped plates 117 of each and every support column 115. The sole plates 125 have on the lower horizontal flange 127 thereof an upper abutment surface 130 for a purpose hereinafter explained and a lower abutment surface 131, the lower abutment surface 131 abutting longitudinally extending grouts 135, the grouts 135 being positioned on the floor or ground 136; the grouts 135 are inclined from the lefthand end of the crib 106 to the right-hand end, as viewed in FIG. 5, for a purpose to be hereinafter ex plained.

Each of the support columns 115 have attached thereto two vertically spaced-apart horizontally extending beams 140, the beams 140 serving to connect each support column 115 with a vertically positioned support beam 141. lnterposed between the vertical beams 141 and the side walls 107 of the crib 106 are a plurality of vertically spaced-apart horizontal and longitudinally extending supports 142, the supports 142 being in the form of tubes or pipes and being welded to the side walls 107 and the vertical beams 141, thereby to provide suitable support for the side walls 107 and the required connection between the walls 107 and the support columns 115. Stainless steel liners 143 extending the entire length of the crib 106 are suitably connected to the sidewalls 107 for a purpose hereinafter to be explained, the stainless steel liners 143 being secured to the walls 107 by a plurality of U-shaped brackets 144, each of the brackets 144 having aninner leg 145, an outer leg 146 and a bight 147 interconnecting the legs, the brackets 144 being positioned over the stainless steel liners 143 and the side walls 107 at appropriate spaced-apartpoints and suitably secured thereto.

Near the top of the crib 106 at spaced-apart points therealong are a plurality of sliding panels 150, the panels 150 being suitably held in place at the top thereof by a contiuous U-shaped channel 151 spaced along the length of the crib 106 and each having two spacedapart legs 151a depending from a horizontally positioned web 152, the legs 1510 being spaced apart a distance sufficient to provide for sliding of the panels 150. The channel 151 is connected to one of the cross-ties 113 and depends downwardly therefrom. The panels 150 are held in place at'the bottom thereof by two Z- shaped angle members 153, the Z-shaped angle members being positioned one on each side of the crib 1 36, each member 153 including a vertical attachment portion 154 suitably connected to the inner'legs of the U-shaped brackets 144, the angle members 153 further including a diagonal member 156 connecting the vertical attachment portion 154 with an upper vertical attachment portion 155, the upper vertical attachment portion providing for the positioning and the support of the sliding panel 150. At spaced-apart points along the panel 150 are inner panels 157 abutting and sliding with the panel 150, the panels 157 are maintained in place at the top thereof by the U-shaped brackets 151 and at the bottorn thereof by a plurality of tension members 158, the tension members 158 being provided with an attachment portion 159 suitably secured to the diagonal member 156 and a continuous rod 160' in tensioning contact with the inner panels 157. The sliding panels 150 are provided at spacedapart points thereon with handles, or knobs 161, the sliding panels .150 providing for easy visual access to the inside of the crib 106 during operation.

The crib 106 is further provided with a loading area 170, as viewed in the left-hand portion of FIG. 1 for loading the rolls 101 into the crib 106, the loading area including two spaced-apart upstanding side walls 171, the side walls 171 being connected by a transversely extending end wall 172, the height of the side walls 171 being adapted to provide for easy manual loading of the rolls 101 into the crib 106. The side walls 171 and end walls 172 are mounted on a horizontally extending platform 175, the platform 175 having a work surface 176 supported by a vertical wall 177. The crib 106 is also provided at the right-hand portion thereof, as viewed in FIG. 1, with a discharge area 180, the discharge area 180 including spaced-apart upstanding side walls 181, the side walls 181 having vertical edges 182 and radial edges 182a and further including outwardly extending flanges 183 attached to and integral with the vertical edges 182, the flanges 183 being for a purpose hereinafter to be explained. The entire crib 106 and conveyor are inclined, as hereinbefore stated, from the loading area 170 to the discharge area 180, the incline'being generally uniform and at a rate of about A inch vertical displacement for every foot of length.

There is also provided a conveyor system 190 for transporting the mass 102 of rolls 101 through the crib 106 from'the loading area 170 to the discharge area 180, the conveyor system 190 including two spacedapart tracks 195, each in the form of an l-beam to provide support as hereinafter explained, the tracks each including a lower generally horizontal flange 196 having an abutment surface 197 resting on the abutment surface 1 19 of eachL-shaped member 1 17 and an upper generally horizontal flange 198 having an abutment surface 199, interconnecting the lower flange 196 and the upper flange 198 is a bight 201. On the abutment surface 199 of each upper flange 198 rests a track bar 205 extending from the loading area 170 to the discharge area 180, the track bars 205 being rectangular in shape and each having an upper abutment surface 206 and a lower abutment surface 207, each of the lower abutment surfaces 207 being suitably connected to the corresponding upper abutment surface 199 of the associated upper flange 198.

The conveyor system 190 further includes a plurality of spaced-apart slats 211 in the form of tubes, the slats 211 being part of an endless conveyor chain 215, the chain includes a plurality of rollers 216 rotatably mounted on shafts 217 adjacent each end thereof, the rollers 216 supported by and in rolling contact with the respective track bar 205. Each of the rollers 216 is held between two spaced-apart links 220, the links 220 having side walls 221, the side walls 221 having therein apertures 222 for receiving therethrough a shaft 217 for rotatably supporting the assocaited roller 216. The side walls 221 of the links 220 further include horizontally extending flanges 223, the horizontally extending flanges 223 are provided with apertures therein (not shown) for mounting the transversely extending tubular slats 211 onto the links 220 by means of headed bolts 225 and square nuts 226-, the outermost link 220 of each two links holding a roller 216 therebetween having a flange 223 extending toward the end of the slat 21 1, the innermost link 220 having a flange 223 extending in the opposite direction. The tubular slats 211 may be provided with a corrosion-resistant vinyl plastic coating for a purpose hereinafter explained.

The endless conveyor chain 215 is supported at the loading area 170 by an idler sprocket 230 rotatably mounted on a shaft 231, suitably journaled in spacedapart mounting plates 232, the mounting plates 232 resting on the l-bearn 125. Adjacent the discharge area 180 is a motor 235 suitably connected to a gear reducer 236 to provide rotation of a drive sprocket 238 by means of a drive shaft 237, the motor 235 providing the driving force forrotation of the endless conveyor chain 215. As may be seen from the Figures and the description herein, there is provided an endless conveyor chain 215 which travels in a continuous loop, support for the top portion of the loop being provided by tracks 205 and support for the bottom part of the loop being provided by the abutment surface 130 of the lower I- beam 125. The outwardly directed flanges 183 in the discharge area 180 provide rigidity to the side walls 181 while the platform 175 and supports 17 7 protect the operators from contact with the moving slats 211 at the loading area 170.

As may be seen by particular reference to FIGS. 11, 12 and 16 to 18, there is also provided a wash solutionsupply system 240 including a plurality of troughs 245. The troughs 245 are spaced-apart longitudinally along the crib 106, as shown particularly in FIG. 1, each trough 245 extends generally transversely to the longitudinal axis of the crib 106 from one side wall 107 to the other and includes a V-shaped wall 246 having integral therewith two inwardly, diagonally downwardly turned flanges 247, the troughs 245 being provided with end plates 248 and endcap 249. All of the troughs 245 are identical in construction, however, the trough 245 -in the second zone, as hereinafter described and shown in relation to the other troughs 245, is immediately connected to the mechanism providing the reciprocal movement of all the troughs 245 and is particularly illustrated in FIGS. 14, 15 and 16.

The above-mentioned trough 245 is held between two spaced-apart mounting plates 255, each of the mounting plates 255 having at the bottom thereof a nut 256 and a headed adjustment screw 257 therein, the screw 257 having a shank portion 258 in contact with the bottom of the trough 245. The trough 245 is suitably secured to the mounting plates 255 by headed bolts 261 positioned in two vertically spaced-apart slots 262 in each of the mounting plates 255. In each of the mounting plates 255, spaced above the end cap 249, are apertures (not shown) through which axles 266 extend, the axles 266 are'aligned along the same horizontal axis and are each a bearing 265 at one end thereof and carry at the other end thereof a roller 267, the rollers 267 being positioned exterior of the mounting plates 255 to provide movement of the plates 255 and hence the trough 245 mounted therebetween.

On either side of the crib 106 there is provided a channel-shaped track 270, the track 270 including an upper flange 271, a lower flange 272 and a web 273 interconnecting the upper and lower flanges, the track 270 extending the entire length of the crib between the loading area 170 and the discharge area 180 and being suitably connected to the cross-ties 113 by angle irons 275, each of the angle irons 275 having a vertical portion 276 suitably attached to the web 273 of the track 270 and a horizontal portion 277 suitably attached to the cross-ties 1 13. Disposed below the bearings 265 on each side of the trough 245 there are two connecting tie rods 280, the tie rods 280 being suitably secured to the mounting plates 255 such as by welding, the tie rods 280 extend longitudinally of the crib 106 and serve to interconnect all of the troughs 245, for a purpose hereinafter to be explained.

Positioned between the two mounting plates 255 at the top thereof is a header 285, the header 285 being 'sealably connected to the left-hand mounting plate, as viewed in FIG. 15, and sealably connected to the righthand mounting plate 255, as seen in FIG. 15, the righthand mounting plate 255 having therein an aperture (not shown) providing communication between the header 285 and the supply of a wash solution. Downwardly depending from the header 285 is a supply pipe 286, the supply pipe 286 having a vertical section 287 suitably connected to the header 285 by a fitting 288, the supply pipe 286 further including a horizontal section 289 lying along the bottom of the trough 245; connecting the vertical section 287 and the horizontal section 289 is an elbow section 291.

Disposed above and connected to the header 285 is a yoke 295, the yoke 295 including a generally rectangular plate 296 having at the bottom thereof two diagonally inwardly and downwardly inclined edges 297 connected by an arcuate edge 298 having a radius of curvature the same as the radius of curvature of the outside surface of the header 285, the edge 298 of the plate 296 being suitably secured to the header 285, such as by welding. The generally rectangular plate 296 is provided with an elongated slot 299, the slot 299 being positioned along the vertical midplane of the plate 296 and extending generally downwardly from the top of the plate 296, the plate 296 being closed at the top thereof by a yoke cap 301 extending across the slot 299 and suitably secured to the plate 296 by bolts 302. There is also provided a yoke drive wheel 305 for effectively connecting the yoke 295 with the drive mechanism, the wheel 305 including a headed shaft 306 mounted in the slot 299 of the yoke 295 from the righthand side as viewed in FIG. 17. The headed shaft 306 has a large diameter portion 307 and a small diameter portion 308, the large diameter portion 307 fitting within the slot 299 and adapted to move vertically within the slot 299, the portion 307 carrying thereon spaced-apart discs 309 for retaining the shaft 306 within the slot 299 and preventing movement thereof transverse to the longer dimension of the slot.

There is also provided a yoke drive assembly 310 including a pair of mounting brackets 311, the mounting brackets 311 including a body portion 312 having'an arcuate edge 313 at the bottom thereof, the arcuate edge 313 being suitably secured to the cross-ties 113 in the center thereof, as shown in FIG. 1 1. Only two crossties 113 carry the yoke drive assembly 310, there being one drive assembly 310 to provide movement for all of the troughs 245. Suitably secured to the mounting brackets 311, which extend diagonally inwardly from the cross-ties 113, are bearings 315 secured to the mounting bracket 311 by bolts 316, the bearings 315 are positioned on both sides of the bracket 311. Suit ably journaled in the bearings 315 closest to the loading area 170 is an idler sprocket shaft 318 carrying thereon an idler sprocket 319, the sprocket 319 being on the right-hand side of the mounting bracket 311.

On the left-hand side of the crib 106 as viewed in FIG. 1 1 is a motor 321. Coupled to the motor 321 is a gear reducer 322, a shaft 323 extending therefrom and driven by the motor 321, the driven shaft 323 being suitably connected thereto by a coupling 324. The drive shaft 323 extends from the motor 321 transversely of the longitudinal dimension of the crib 106 to the mounting brackets 311 which are mounted at the middle of the cross-ties 113. At the distal end of the drive shaft 323 from the motor 321 is a drive sprocket 329, the sprocket being suitably secured to the drive shaft 323 for rotation therewith and carrying thereabout a chain 330, the chain 330 forming an endless loop between the drive sprocket 329 and the idler sprocket 319. As may be seen from the Figure, the

smaller diameter portion 308 of the headed shaft 306 extends through the chain 330 and therefore as the chain 330 travels in its closed path as viewed in FIG. 14, the shaft 306 is carried therewith and therefore also the yoke 295. When the shaft 306 and the yoke 295 encounter either the idler sprocket 319 or the drive sprocket 329, the shaft 306 travels downwardly or upwardly in the slot 299 as the case may be, particularly as seen in the phantom view in the left-hand side of FIG. 14. As may be seen, therefore, the troughs 245 travel in a reciprocal path as defined by the endless chain 330, all the troughs being connected by the connecting tie rods 280 simultaneously to travel reciprocal paths overlying the slots 211 along the length of the crib 106 parallel to the longitudinal axis thereof. Each of the reciprocal paths defined by the troughs 245 forms a zone through which the mass 102 of rolls 101 is transported, the purpose being hereinafter explained.

A temperature gage 335 is connected to an inlet pipe 336 leading to the header 285. Depending from the inlet pipe 336 is a connecting pipe 337, the connecting pipe 337 having a vertically downwardly extending portion 338 and an angle portion 339, the end of the angle portion 339 being connected to a flexible hose 340. While the Figures show only one temperature gage, it is to be understood that each of the sections may be provided with a temperature gage. As may be realized, any of the particular sections of the crib 106 may be provided with the drive motor 321, however, it is shown here that the second section from the loading area 170 has the motor. As seen particularly in FIG. 17, the other sections of the crib 106 are provided with troughs 245 suitably mounted between two mounting plates 345, each of the mounting plates 345 having at the bottom thereof a nut 346 carrying therein a headed adjustment screw 347 having a shank 348, the shank 348 being in contact with and providing adjustment for the trough 245. Each of the troughs 245 is suitably connected to the mounting plates 345 by headed bolts 351 in two slots 352 provided in the mounting plates 345. The mounting plates 345 are carried by the rollers 267 and carry thereon angle bracket 355, the angle brack-- ets 355 having a vertical portion 356 suitably secured to the mounting plates 345 such as by welding and a horizontal section 357 suitably supporting a support plate 358. The support plates 358 each carry thereon a supply pipe 361, the supply pipes 361 each includes a horizontal pipe 362 suitably secured to the associated support plate 358 by two U-shaped brackets 363 having threaded ends for receiving fastening nuts 364 thereon. Connected to the left-hand portion of the horizontal pipe 362, as seen in FIG. 17, is an elbow 367 providing connection between the horizontal pipe 362 and a vertical feed pipe 368, the vertical feed pipe 368 terminating within the trough 245. On the right-hand portion of the supply pipe 361 is a vertical part 371 and a stopper 372, the vertical part 371 of the supply pipe 361 being connected to a flexible hose 340 by a connecting'pipe 377. As best seen in FIG. 18, wash solution 375 introduced into the troughs 245 overflows therefrom and down the sides 246 thereof the flanges 247 providing for smooth flow therealong to form a plurality of cascades of wash solution 376 which fall onto the mass 102 of tightly wound rolls 101 being transported through the crib 106 by the conveyor system 190.

As best seen in FIG. 11, there is disposed below the tubular slats 211 supporting the mass 102 of tightly wound rolls 101, a drip pan 380, the drip pan 380 being inclined downwardly from the left-hand side of the crib 106 to the right-hand side of the crib. The drip pan 380 consists of a plurality of sheets 385, each of the sheets 385 being roughly the same length as the zones defined by the reciprocal paths of the troughs 245, the drip pan 380 having at spaced-apart points thereon a plurality of low ribs 381 and at the outermost ends thereof high ribs 382. Each of the high ribs 382 is formed by an upwardly extending portion 386 of one of the sheets 385 and a hook-shaped portion 387 of the adjacent sheet 385, the upwardly extending portion 386 fitting with the hook-shaped portion 387 to form the high rib 382. The drip pan 380 also includes an attachment flange 383 on the left-hand side thereof which is attached to the abutment surface 199 of the upper flange 198 of I- beam 195.

On the right-hand side of the crib 106, as viewed in FIG. 1 1, there is a collecting trough 390, the collecting trough 390 extending the length of the crib 106 and including an upstanding side wall 391 which receives therein a lip 384 connected to the drip pans 380, the collecting trough 390 further including a second upstanding side wall 392 spaced from the wall 391 and suitably attached to the I-beam a curved bottom portion 393 interconnects the upstanding side walls 391 and 392. Disposed horizontally across the trough 390 and suitably connected to the upstanding side walls 391 and 392 is a screen filter 395, the filter 395 being disposed below the lip 384 of the drip pans 380 for filtering the drained wash solution collected in the drip pan 380. Depending from the curved bottom portion 393 of the collecting trough 390 at spaced-apart points therealong are a plurality of drain hoses 398 suitably secured to the trough 390 by fittings 397, each of the drain hoses 398 leading to a collecting basin 400 or 421.

As may be seen from the above description, wash solution 375 introduced into each of the troughs 245 overflows therefrom to form cascades 376 which fall onto the mass 102 of tightly wound rolls 101 transported through the crib 106 by the conveyor system 190. As the wash solution 375 contacts the multi-layer rolls 101, the rolls 101 become saturated to the innermost layer thereof with the wash solution 375, excess wash solution falling from the rolls 101 through the tubular slats 211 of the conveyor system 190 onto the drip pan 380 and then into the collecting trough 390, the trough 390 being divided into sections to prevent mixing of the wash solution collected from each zone. From the collecting trough 390 the wash soltuion flows into the collecting basins 400 and 421.

The collecting basin 400 and the mixing station 410 are adjacent the loading area 170 and are different from the sectional mixing stations 420 and the collecting basins 421 therefor, the collecting basin 400 and mixing station 410 for collecting wash solution draining from the rolls 101 and providing make-up solution draining from the rolls 101 and providing make-up solution to be added thereto to maintain constant the cascade 376 in the first zone being hereinafter described. The collecting basin 400 may be entirely buried within the ground 136 or it may extend partly outwardly therefrom, the basin 400 being generally cylindrical in shape and including a side wall 401 and a bottom wall 402, the side wall 401 terminates in its upper-most edge in a lip 403, the basin 400 serving as a reservoir for the wash solution as hereinafter explained. Upwardly disposed from the basin 400 is a horizontally extending platform 405, the platform 405 having therein a central aperture 406 and a motor stand 407 spaced from the platform 405 and parallel thereto, the stand 407 being positioned over the aperture 406; a plurality of downwardly extending legs 408 connect the stand 407 with the platform 405 and support the stand thereon. The first wash solution mixing station 410 further includes an inner mixing tube 415 and an outer return tube 416 disposed concentrically about the inner tube 415 to maintain the liquid in the mixing tube 415 at a predetermined level. The outer return tube 416 is closed at the bottom end thereof by base plate 417, the inner mixing tube 415 being open at the bottom thereof is positioned with the bottom thereof spaced above the bottom of the outer tube 416 and supported thereat by supports 418 thereby providing communication between the inner mixing tube 415 and the outer return tube 416, it being noted that the upper end of the inner mixing tube 415 extends above the upper end of the outer return tube 416 and the liquid level in the tube 415 is determined by the point at which liquid flows from the tube 416. A motor 430 positioned on a motor stand 407 is connected to a gear reducer 431, the gear reducer 431 being in turn connected to a stirrer 435, the motor 430 and gear reducer 431 cooperating to provide for rotation of the stirrer 435. The stirrer 435 including a longitudinally downwardly extending shaft having thereon a plurality of spaced-apart mixing pins 436 transversely extending therefrom. Attached to the inner wall ofthe inner mixing tube 415 extending transversely to the longitudinal axis of the tube 415 are a plurality of spaced-apart mixing pins 437, the mixing pins 437' being alternately positioned with the mixing pins 436 extending from the stirrer 435. The mixing pins 437 acting as baffles to provide with the mixing pins 436 on the stirrer 435 upon rotation thereof mixing action within the tube 415.

Disposed on the platform 405 about the aperture 406 are a plurality of liquid additive storage containers 440 and 441, each of the containers 440 and 441 have an outlet 445 and 446 respectively extending therefrom in communication with the inner mixing tube 415. Connected to the outlets 445 and .446 are solenoid valves 448 and 449 respectively for controlling the amount of liquid additive flowing from the containers 440 and 441 throughlthe outlets 445 and 446 to the mixing tube 415. Also disposed on the platform 405 is a solid additive storage hopper 450, the hopper 450 including a triangular front wall 451 inclined inwardly and downwardly toward the center of the platform 405 and spaced-apart triangular side walls 452 also inwardly and downwardly inclined, the storage hopper 450 further including a straight back wall 453 and an outwardly extending lip 454 disposed about the top edge of the hopper 450. The bottom of the hopper 450 contains an aperture (not shown) leading to a corresponding aperture (not shown) in a feed screw housing 460, the feed screw housing 460 resting on the platform 405 intermediate the platform and the hopper 450 and having a closed end 461 extending over the aperture 406 and having an opening 462 in the bottom thereof in registry with the aperture 406 in the platform 405. Disposed within the housing 460 is a shaft 465 carrying thereon a wormscrew 466 for feeding the solids from the hopper 450 into the mixing tube 415. The shaft 465 passes through a mounting block 467 and a bearing assembly 468, the entire mounting block and bear'ing assembly rests on a platform 469. As seen in FIG. 9, a motor 470 drives a shaft 471 connected to a drive sprocket 472; an endless belt 474 connects the drive sprocket 472 with a sprocket 473 mounted on the shaft 465, thereby to provide rotation of the wormscrew 466 upon rotation of the shaft 465 thereby to transmit solids 477 from the hopper 450 into the mixing tube 415.

There is further provided a water inlet pipe 480 and a solenoid valve 481 for controlling the amount of water flowing therethrough, the inlet pipe 480 being fixed to the inner wall of the mixing tube 415 to introduce thereinto water tangentially to the inner wall of tube 415 to introduce there into water tangentially to the inner wall of tube 415 to form a vortex therein,.

thereby to provide improved flushing action of the water to keep the walls 415 clean.

As may be seen, freshly prepared wash solution 485 of the water mixed with the additives in tube 415 flows downwardly through tube 415 from the bottom thereof into tube 416 and upwardly therethrough to overflow therefrom and downwardly along the outer wall thereof into the basin 400 where it is mixed with the drained wash solution flowing from the mass 102 of tightly wound rolls 101 through the conveyor sltas 211 into the drip pan 380 and trough 390 to be transported to the basin 400 by the hose 398, the mixed wash solution of make-up solution 485 and drained solution being designated by numeral 486.

Also disposed within the basin 400 is a pump 490; an off-on switch 491 connected to a shaft 492 leading to a float 493 operates the solenoid valve 481. The pump 490 is supported by means of a shaft 492 on a base 495 and is of the sump type thereby to provide pumping action for the mixed wash solution 486 through the base 495 upwardly through a suitable fitting 496 and a hose 497, the hose 497' leading to a heater 500.

The heaters 500 are of the conventional gas burning type and are mounted by struts 501 to supporting columns l 15. The heaters 500 include a body portion 502, a hood disposed thereabove 503 and a vent portion 504 for hot gases to pass therethrough. There is also provided a gas header 506 and a gas supply pipe 507 leading from the header 506 to a gas flow control device 508 in commmunication with the heater 500, a suitable fitting 509 connects the gas supply pipe 507 with the control 508.

The sectional mixing stations 420 may be of the same type as the mixing station 410 or may be of a simpler construction as illustrated, the sectional stations 420 consisting of basins 421 similar in all respects to basin 400 and including a supply platform 424 vertically spaced from the basin 421 and providing support for a solid additives supply 422 and a liquid additives supply 423, the supplies 422 and 423 being in communication with the basin 421. A feed screw shaft 425 similar in all respects to the feed screw shaft 465 and associatd hardware is also provided in the sectional mixing stations 420 for feeding the solid additives from the supply 422 to the basin 421. As hereinbefore explained, the sectional mixing stations 420 may be of simpler construction than the first mixing station 410 due to the fact that little wash solution is lost in the later zones, whereas large quantities of make-up wash solution are continuously needed in the first station 420 to initially wet the rolls 101 in the first zone. Each of the sectional mixing stations are provided with solenoid valves as hereinbefore described, the valves being operatively responsive to the level of wash solution-in the basins 421 for controlling the amount of solid additives, liquid additives and water introduce into the basin 421. Each of the stations 420 is provided with a pump as hereinbefore described to pump the wash solution to an associated heater 500, all as described above.

In operation, an operator designated by the numeral 515 receives the rolls of tightly wound cloth in slings 516 consisting of eight rolls 101 of tightly wound, multi-layer rolls of pervious cloth, the slings 16 being transported by a conveyor 517 to the operator 515. Each roll 101 may consist of 50 yard long continuous toweling of the type used in closed loop towel dispensing machines, each roll 101 weighing about 6 pounds when dry and absorbing about 250 percent of their own weight in wash solution, therefore to weigh about 20 pounds when saturated. The rolls 101 of toweling introduced into the crib 106 at the loading area 170 to form a randomly arranged mass 102 about 4 feet in height are dry and therefore absorb large quantities of wash solution from the cascade 376 of wash solution overflowing from the trough 245 in the first zone, the first zone being defined by the reciprocal path that the trough 245 most adjacent to the loading area 170 travels. Since the rolls 101 when introduced into the crib 106 absorb huge quantities of wash solution, the first mixing stage 410 opeates more or less continuously to provide freshly prepared wash solution to the first trough 245.

The fresh wash solution 485 is prepared upon activation of the solenoid valve 481 by the introduction of water through the water supply pipe 480, the water being introduced simultaneously with the additives, the water flow-is either on or off and is controlled by the switch 491, the water being introduced tangentially to the inner mixing tube 415 thereby to form therein a vortex of water. The level of water in the inner mixing tube 415 as previously explained is maintained by the height of the wash solution in the outer return tube 416 thereby to insure the formation of a vortex of water within the inner tube 415. Additives introduced into the inner mixing tube 415 by the activation of solenoid valves 448, 449 and the solenoid control (not shown) for the motor'470 mix with the water in the inner mixing tube 415 due to the vortex formed by the water and the mixing action provided by rotation of the stirrer 435, the mixing pins 436 disposed thereon and the baffles or mixing pins 437 disposed on the inner wall of the tube 415. The mixed wash solution 485 flows downwardly through the mixing tube 415 and into the outer return tube 416 and upwardly therethrough to overflow from the top edge thereof into the basin 400. In the basin 400 there is a mixture 486 of the freshly prepared wash solution 485 and the wash solution drained from the rolls 101 and returned to the basin 400 by the tube 398, operation of the mixing station 420 to provide a constant volume of ,wash solution to the first trough 245 and therefore to the cascade 376.

The wash solution may contain various fatty acid soaps for grease removal and non-ionic detergents or it may contain alkali such as sodium hydroxide which may be added to the wash solution in either liquid or solid form, additionally other enzyme materials may be added as the case requires. Germ control may be attained by the use of chlorozone or other germ control agents. pH control may also be effected by the use of various acids. It is also contemplated that various other additives known in the washing art, such as phosphates, other buffers, soaps, detergents and alkalies may be used. It is seen therefore that each cascade 376 may contain one or more additives depending on the type of soil to be loosened. The heater 500 for the first zone supplies wash solution to the first trough 245 at a temperature' of about F. to about 200F., the elevated temperature providing improved soaking action.

As the conveyor system transports the mass 102 of rolls 101 therealong and through the crib 106, the reciprocating troughs 245 combine therewith to periodically apply the wash solution in the form of cascades 376 thereto. Continual drainage of the excess wash solution is provided by the open slat conveyor chain 215 thereby to allow the excess wash solution to continually drain therethrough and into the drip pan 380 thereby to prevent the stagnation of the wash solution. The excess wash solution applied in each zone is collected separately by the drip pan 380 due to the high ribs 382 which are positioned at the terminal ends of sheets 385, the sheets 385 being equal in length to each reciprocal path for each trough 245 thereby separately to maintain the was solutions in each zone. The wash solution from each zone collected on the drip pan 380 flows therefrom into the collecting trough 390 and thereafter through the drain hoses 398 back into the basins 400 and 421 where it is again mixed with make-up wash solution 485 freshly prepared and recirculated by means of the pumps 490 upwardly through the flexible hoses 497 to be reheated in heaters 500 and introduced therefrom to the respective trough 245.

As the mass 102 of rolls 101 is transported by the conveyor system 190 through the crib 106, it passes through consecutive zones, the zones being formed by the reciprocal path of each and every trough 245. In each zone the relative movement provided by the conveyor chain 215 and the troughs 245 serves to periodically apply the wash solution in the form of a cascade 376 from the troughs 245 onto the surface of the rolls 101 of tightly wound pervious cloth.

Clearly, it is seen that after the initial contact with the wash solution, the amount of wash solution draining through the rolls 101 is essentially equal to the amount of wash solution added thereto and therefore, the sectional mixing stations 420 are not required to provide the large quantities of make-up wash solution 485 that the first mixing station 410 is required to produce. Thus, the sectional mixing stations 420 generally provide little if any make-up wash solution, but serve principally to recirculate the collected wash solution from each and every zone to the heater 500 associatd with that zone and from the heater 500 to the associated trough 245, each of the troughs 245 moving along its own reciprocal path, the sum total of the lengths of the reciprocal paths equal to the length of the crib 106 from the loading area 170 to the discharge area 180.

In addition to the soil-loosening action provided by saturation with the wash solution, improved loosening action may be attained by means of thermal shock introduced to the mass 102 of rolls 101 by subjecting the rolls 101 sequentially to wash solutions at different temperatures. For instance, wash solution may be supplied to the mass 102 of tightly wound rolls 101 at an elevated temperature of from about 120F. to about 200F. and in an adjacent zone wash solution may be supplied to the mass 102 of tightly wound rolls 101 at a temperature of about 50F. thereby to provide thermal shock to the mass 102 of tightly wound rolls 101 and thereby to further loosen soil therefrom.

An advantage of the present invention is in the ability to vary the loading capacity of the crib 106 and thereby the production capacity by adding or deleting sections, as most clearly shown in FIGS. 2 to 4. Assuming that each of the sections between the support columns 115 is about feet in length, then FIG. 2 shows a crib of about feet in effective length, FIG. 3 shows a crib of about 40 feet in effective length and FIG. 4 shows a crib of about 40 feet in effective length. The flexibility obtained by assembling the soil loosening apparatus 105 of the present invention in uniform lengths or sections is particularly important in a growing economy wherein a plant processing continuous towels is never burdened with over-sized equipment or machinery which becomes obsolete after 1 or 2 years when production demands have increased.

For an apparatus as shown in FIG. 2, the plant capacity is between 1,000 and 3,000 rolls per day. The apparatus could be loaded with up to 1,600 towels at one time, and these 1,600 towels would be expelled and washed during the 4 morning hours and during the 4 afternoon hours, the machine would again be loaded with 1,600 towels and stopped. During the evening hours troughs 245 could continue to reciprocate while the conveyor system was halted, thereby to continue applying the wash solution to the rolls of toweling and therefore all towels would be subjected to the wash solutions for 16 hours. As production demand increased, the same machine could be operated in shifts. To attain the rate of seven towels per minute, the machine could i be operated for the 4 morning hours and loaded as the towels are discharged from the discharge area. By noon, 1,600 towels would have been processed and the machine would again be loaded and stopped. During the first 4 hours of the second shift, the loading and washing process would again be repeated. The towels loaded during the 4 morning hours would therfore be subjected to the wash solution for 8 hours and the towels loaded during the first 4 hours of the second shift would be subjected to the wash solution for 12 hours, the total capacity would then be 3,200 towels per day.

For the 40 foot apparatus shown in FIG. 3, a capacity of 3,200 is achieved. For the same rate of seven towels per minute, towels are loaded and washed for 8 hours, the conveyor being stopped during the night, but the wash solution being continually applied by the troughs. In this manner, all towels in the machine are subjected to the wash solution for 24 hours and in this manner the two shifts required to process 3,200 towels in the apparatus shown in FIG. 2, has been reduced to one shift in the apparatusin FIG. 3. If production demands again increase, the 40 foot machine can be operated for two shifts. For instance, towels can be loaded and washed during the first 8 hour shift producing 3,200 towels at seven towels per minute. This process can be repeated during the second shift and thereafter the conveyor be stopped during the third shift while the wash solution is continually applied to the towels. Therefore, one half of the towels processed are subjected to the wash solution for 8 hours and the other half for 16 hours.

Again, if production demands increase, the machine can be extended to six or eight sections of 10 feet each, for instance as shownin FIG 4. Themodular construction of all component parts makes such an expansion feasible or conversely, on the other hand, if production capacity decreases, sections can be removed from the machine as easily as being added thereto. In each case however the rolls 101 are subjected to the wash solution for a time in excess of 8 hours, the minimum time required for effective soil-loosening action and in some cases the rolls 101 are subjected to the wash solution for up to 24 hours.

In a constructional example, the crib 106 contains stainless steel liners 143, the side walls 107 and the cross-ties 1 13 forming a chamber 10 feet wide by 4 feet high, the length of the crib 106 being variable as hereinbefore described, but conveniently being made in 10 feet long sections. The conveyor chain 215 consists of tubular slabs 12 feet long, the chain 215 being positioned out of contact with the wash solution. The I- beams 195 are pitched downwardly from the loading area to the discharge area to utilize gravity to decrease the torque on the drive motor. The side walls 171 of the loading area 170 are about 2 feet in length and 4 feet in height and are spaced apart about 10 feet. The troughs 245 are reciprocable along a path 10 feet in length to correspond to the 10 feet sections of the crib 106, each trough completes its reciprocal motion in approximately 1 minute to evenly distribute the cascade 376 of wash solution 376 onto the mass 102 of rolls 101 which is 4 feet high.

With regard to the first mixing station 410, the bottom of the inner mixing tube 415 is spaced about 3 inches from the bottom of the outer tube 416 and the top edge of the outer tube 416 is about 6 inches below the water inlet 480. For a residence time in the tube 415 of about 30 seconds for water entering the tube 415 at a rate of about 13 gallons per minute, the tube 415 is 4 feet 6 inches high. The solenoid-operated water-inlet valve 481 and all additive supplies are electrically interlocked for either a high-low or an on-off operation controlled by the float switch 491 in the first station 410.

While the above described soil-loosing apparatus 105 particularly illustrates four zones and four flooding troughs 245 therein, it is clear that the invention isintended to cover a machine of any number of zones, from one to whatever capacity is required, the operating principle being essentially the same for all. The important features of the invention being the V-shaped flooding troughs 245 used to assure an evenly distributed cascade 376 of wash solution 375 over the mass 102 of tightly wound rolls 101 all without the usual spray nozzle systems involving the problems of clogging and complicated pumping systems to provide the required static pressure for the spray nozzle. Additionally, the gravity movement of the wash solution 375 through the mass 102 of tightly wound rolls 101 greatly enhances its soil-loosening action to provide soil loosening not possible by total imersion in a liquid even if the liquid is mechanically agitated. Another feature of this invention is the continual draining of the wash solution 375 from the mass 102 of tightly wound rolls 101. The periodic application of the wash solution being sufficient to provide saturation of the tightly wound rolls 101 to the innermost layer thereof upon the exit of the rolls 101 to the innermost layer thereof upon the exit of the rolls 101 from the last zone of the machine 105 into the discharge area 180.

lt may be seen therefore that there has been provided a method for loosening soil from a mass 102 of randomly arranged, tightly wound, multi-layer rolls 101 of pervious cloth including a foraminous conveyor 215 for transporting the mass 102 of tightly wound rolls 101 through a crib 106 surrounding the conveyor 215 for retaining the mass 102 of tightly wound rolls 101 thereon, a supply mechanism 240 associatd with the crib 106 and including a plurality of troughs 245 overlying the conveyor 215, the troughs 245 being operable to produce cascades 376 of wash solution 375 from the troughs 245 directed onto the conveyor 214 and the mass 102 of tightly wound rolls 101 supported thereby, the troughs 245 being respectively reciprocable along longitudinally aligned paths overlying the conveyor 215 thereby to form a plurality of zones, operation of the conveyor 215 serving to move the mass 102 of tightly wound rolls 101 from the loading port 170 to the discharge port 180 through the plurality of zones formed by the cascades 376 of wash solution 375, the conveyor 214 and the crib 106 being constructed and arranged for the continual draining of excess wash solution from the mass 102 of tightly wound rolls 101 on the conveyor 215 during the passage thereof from the loading port 170 to the discharge port 180, a drip pan 380 and collecting trough 390 associated with each zone for collecting excess wash solution draining from the mass 102 of tightly wound rolls 101 transported by the conveyor 215 through each of the zones and for recirculating to the associated one of the troughs 245 the excess ing basins 400 and 421 and the mixing stations 410 and 420 for adding make-up-wash solution respectively to the drained wash solution from each zone in response to depletion of the drained wash solution from the respective zone to maintain substantially constant in volume the cascades 376 of the wash solution directed onto the conveyor 215 and the mass 102 of tightly wound rolls 101 supported thereby, a plurality of temperature controlled devices 500 for controlling the temperature of the plurality of cascades 376 of wash solution thereby to apply the wash solution in at least some of the zones at an elevated temperature of about F. to about 200F. with respect to the wash solution at about 50F. in an adjacent one of the zones sequentially to subject the mass 102 of tightly wound rolls 101 to wash solutions at different temperatures to induce thermal shock in each of the tightly wound rolls 101, the application of the plurality of cascades 376 of wash solution to the mass 102 of tightly wound rolls 101 directing the transport thereof the conveyor 215 through the zones serving to maintain the surfaces of the rolls 101 wet for a time sufficient to saturate each of the tightly wound rolls 101 to the innermost layer thereof upon exiting from the last of the zones, whereby substantially to loosen all of the soil disposed on and in the cloth forming the tightly wound rolls 101 during the transportation thereof through the crib 106 on the conveyor 215.

There has also been provided an apparatus for preparing wash solution 485 comprising an elongated inner cylinder 415 being open at both ends, an elongated outer cylinder 416 disposed about the inner cylinder 415 and spaced therefrom to provide an annulus therebetween, the outer cylinder 416 being closed at the bottom end 417 thereof and being spaced at the bottom end 417 thereof from the bottom end of the inner cylinder 415, the outer cylinder 416 having the top edge thereof spaced below the top edge of the inner cylinder 415, a reservoir 400 for holding freshly prepared wash solution 485 disposed about the bottom 417 of the outer cylinder 416, the reservoir 400 being so positioned to receive freshly prepared wash solution 485 flowing from the outer cylinder 416, a stirrer 435 disposed in the inner cylinder 415 including a plurality of members 436 extending outwardly from the stirrer 435, a plurality of baffles 437 extending from the inner walls of the inner cylinder 415, the baffles 437 and the outwardly extending members 436 cooperating upon rotation of the stirrer 435 to provide a mixing action in the inner cylinder 415, a water supply pipe 480 for introducing water into the inner cylinder 415 tangentially to the inner wall thereof, the water supply pipe 480 being positioned below the top edge of the inner cylinder 415 and above the top edge of the outer cylinder 416, thereby to produce a vortex of water inside the inner cylinder 415, first control means 481 associated with the water supply pipe 480 for controlling the flow .of water therethrough, an additive supply 440, 441 and 450 in communication with the inner cylinder 415, second control means including solenoid valves 448 and 449 associated with the additive supplies 440, 441 and 450 for controlling the amount of additives therefrom to the inner cylinder 415 for mixing with the vortex of water, a pump 490 for pumping wash solution 486 from the reservoir 400, and means including a float 493 responsive to the level of the wash solution 486 in the reservoir 400 for operating the first and second control means including solenoid valves 481, 448 and 449 to introduce water and additives to the inner cylinder 415, whereby the additives introduced into the inner cylinder 415 with the water are mixed with the vortex formed thereby and flow downwardly through the inner cylinder 415 into the outer cylinder 416 and upwardly through the annulus formed between the inner cylinder 415 and the outer cylinder 416 to flow from the outer cylinder 416 into the reservoir 400 to maintain constant the level of wash solution 486 in the reservoir 400 when the pump 490 is operative to pump wash solution 486 therefrom.

While there has been described what is at present considered to be the preferred embodiment of the invention, it will be understood that various modifications may be made therein and it is intended to cover in the appended claims all such modifications as fall within the true spirit and scope of the invention.

What is claimed is:

l. A method of loosening soil from a mass or randomly arranged, tightly wound, multi-layer rolls or pervious cloth comprising the steps of applying a wash solution to the mass of pervious cloth to maintain the surfaces thereof wet for a time sufficient to saturate the cloth to the innermost layer thereof, while continually draining excess wash solution from the mass of pervious cloth, whereby to saturate the pervious cloth to the innermost layer thereof with the wash solution and thus to loosen the soil from the cloth.

2. The method set forth in claim 1, wherein the wash solution is applied to the mass of pervious cloth from above the mass of pervious cloth.

3. The method set forth in claim 1, wherein the wash solution is applied to the mass of pervious cloth as a cascade.

4. The method set forth in claim 1, wherein the wash solution is applied to the mass of pervious cloth for a period in excess of 1 hour.

5. The method set forth in claim l, wherein the wash solution is applied to the mass of pervious cloth for from about 4 hours to about 8 hours.

6. The method set forth in claim 1, wherein the wash solution is periodically applied to the mass of pervious cloth.

7. The method set forth in claim 1, wherein the temperature of the wash solution is between about 50F. and about 200F.

8. The method set forth in claim 1, and further comprising the step of recirculating the excess wash solution drained from the mass of pervious cloth onto the mass of pervious cloth.

9. A method of loosening soil from a mass of randomly arranged, tightly wound, multi-layer rolls of pervious cloth comprising the steps of forming a cascade of wash solution, applying the cascade of wash solution to the mass of pervious cloth to maintain the surfaces thereof wet for a time sufficient to saturate the pervious cloth to the innermost layer thereof, while continually draining excess wash solution from the mass of pervious cloth, providing relative movement between the cascade of wash solution and the mass of pervious cloth whereby to saturate the pervious cloth to the innermost layer thereof with the wash solution and thus to loosen the soil from the cloth.

10. The method set forth in claim 9, wherein the mass of pervious cloth is transported along a predetermined path past the cascade of wash solution.

11. The method set forth in claim 9, wherein the cascade of wash solution is reciprocated along a predetermined path past the mass of pervious cloth.

12. The method set forth in claim 9, wherein the relative movement is provided by transporting the mass of pervious cloth along a predetermined path, and providing reciprocal movement of the cascade of wash solution in the direction of travel of the mass of pervious cloth along said predetermined path.

13. A method of loosening soil from a mass of randomly arranged, tightly wound, multi-layer rolls of pervious cloth comprising the steps of forming a cascade of wash solution, transporting the mass of tightly wound rolls through said cascade of wash solution, while continually draining excess wash solution from the mass of tightly wound rolls, collecting the drained excess wash solution and rcirculating the same to said cascade, adding make-up wash solution to the collected drained wash solution in response to depletion of the drained wash solution to maintain the cascade of wash solution supplied to the mass of tightly wound rolls essentially constant in volume, whereby to maintain the surfaces of the mass of tightly wound rolls wet for a time sufficient to saturate each of the tightly wound rolls to the innermost layer thereof with the wash solution and thus to loosen the soil from the cloth.

14. The method set forth in claim 13 wherein the make-up wash solution is added automatically in response to the depletion of the collected drained wash solution.

15. A method of loosening soil from a mass of randomly arranged, tightly wound, multi-layer rolls of pervious cloth comprising the steps of forming a plurality of cascades of wash solution in a plurality of zones, transporting the mass of tightly wound rolls through said plurality of zones, while continually draining excess wash solution from the mass of tightly wound rolls, whereby to maintain the surfaces of the tightly wound rolls wet in each zone for a time sufficient so that upon exiting from the last zone the innermost layers of the tightly wound rolls are saturated thus to loosen the soil from the cloth.

16. The method set forth in claim 15, wherein certain of the cascades of wash solution have different chemical compositions than other of the cacades.

17. The method set forth in claim 15, wherein the wash solution in one zone contains a fatty-acid soap.

18. The method set forth in claim 15, wherein the wash solution in one zone contains a germ-control agent.

19. The method set forth in claim 15, wherein the wash solution in one zone is alkaline.

20. The method set forth in claim 15, and further- I comprising the step of respectively automatically recirculating to each zone the wash solution drained therefrom separately to maintain the wash solution in each zone. 

2. The method set forth in claim 1, wherein the wash solution is applied to the mass of pervious cloth from above the mass of pervious cloth.
 3. The method set forth in claim 1, wherein the wash solution is applied to the mass of pervious cloth as a cascade.
 4. The method set forth in claim 1, wherein the wash solution is applied to the mass of pervious cloth for a period in excess of 1 hour.
 5. The method set forth in claim 1, wherein the wash solution is applied to the mass of pervious cloth for from about 4 hours to about 8 hours.
 6. The method set forth in claim 1, wherein the wash solution is periodically applied to the mass of pervious cloth.
 7. The method set forth in claim 1, wherein the temperature of the wash solution is between about 50*F. and about 200*F.
 8. The method set forth in claim 1, and further comprising the step of recirculating the excess wash solution drained from the mass of pervious cloth onto the mass of pervious cloth.
 9. A method of loosening soil from a mass of randomly arranged, tightly wound, multi-layer rolls of pervious cloth comprising the steps of forming a cascade of wash solution, applying the cascade of wash solution to the mass of pervious cloth to maintain the surfaces thereof wet for a time sufficient to saturate the pervious cloth to the innermost layer thereof, while continually draining excess wash solution from the mass of pervious cloth, providing relative movement between the cascade of wash solution and the mass of pervious cloth whereby to saturate the pervious cloth to the innermost layer thereof with the wash solution and thus to loosen the soil from the cloth.
 10. The method set forth in claim 9, wherein the mass of pervious cloth is transported along a predetermined path past the cascade of wash solution.
 11. The method set forth in claim 9, wherein the cascade of wash solution is reciprocated along a predetermined path past the mass of pervious cloth.
 12. The method set forth in claim 9, wherein the relative movement is provided by transporting the mass of pervious cloth along a predetermined path, and providing reciprocal movement of the cascade of wash solution in the direction of travel of the mass of pervious cloth along said predetermined path.
 13. A method of loosening soil from a mass of randomly arranged, tightly wound, multi-layer rolls of pervious cloth comprising the steps of forming a cascade of wash solution, transporting the mass of tightly wound rolls through said cascade of wash solution, while continually draining excess wash solution from the mass of tightly wound rolls, collecting the drained excess wash solution and recirculating the same to said cascade, adding make-up wash solution to the collected drained wash solution in response to depletion of the drained wash solution to maintain the cascade of wash solution supplied to the mass of tightly wound rolls essentially constant in volume, whereby to maintain the surfaces of the mass of tightly wound rolls wet for a time sufficient to saturate each of the tightly wound rolls to the innermost layer thereof with the wash solution and thus to loosen the soil from the cloth.
 14. The method set forth in claim 13 wherein the make-up wash solution is added automatically in response to the depletion of the collected drained wash solution.
 15. A method of loosening soil from a mass of randomly arranged, tightly wound, multi-layer rolls of pervious cloth comprising the steps of forming a plurality of cascades of wash solution in a plurality of zones, transporting the mass of tightly wound rolls through said plurality of zones, while continually draining excess wash solution from the mass of tightly wound rolls, whereby to maintain the surfaces of the tightly wound rolls wet in each zone for a time sufficient so that upon exiting from the last zone the innermost layers of the tightly wound rolls are saturated thus to loosen the soil from the cloth.
 16. The method set forth in claim 15, wherein certain of the cascades of wash solution have different chemical compositions than other of the cascades.
 17. The method set forth in claim 15, wherein the wash solution in one zone contains a fatty-acid soap.
 18. The method set forth in claim 15, wherein the wash solution in one zone contains a germ-control agent.
 19. The method set forth in claim 15, wherein the wash solution in one zone is alkaline.
 20. The method set forth in claim 15, and further comprising the step of respectively automatically recirculating to each zone the wash solution drained therefrom separately to maintain the wash solution in each zone.
 21. A method of loosening soil from a mass of randomly arranged, tightly wound, muti-layer rolls of pervious cloth comprising the steps of forming a plurality of cascades of wash solutions in a plurality of zones, reciprocating each cascade of wash solution in each zone along a predetermined path, transporting the mass of tightly wound rolls through said plurality of zones, while continually draining excess wash solution from the mass of tightly wound rolls, whereby to maintain the surfaces of the tightly wound rolls wet in each zone for a time sufficient so that upon exiting from the last zone the innermost layers of thE tightly wound rolls are saturated thus to loosen the soil from the cloth.
 22. A method of loosening soil from a mass of randomly arranged, tightly wound, multi-layer rolls of pervious cloth comprising the steps of forming a plurality of cascades of wash solution in a plurality of zones, wherein the wash solution in certain of said zones is at an elevated temperature with respect to the wash solution at an adjacent one of said zones, transporting the mass of tightly wound rolls through said plurality of zones sequentially to subject the mass of tightly wound rolls to wash solutions at different temperatures to induce thermal shock in each of the tightly wound rolls, while continually draining excess wash solution from the mass of tightly wound rolls, whereby to maintain the surfaces of the tightly wound rolls wet for a time sufficient to saturate the same to the innermost layer thereof with the wash solution and thus to loosen the soil from the cloth.
 23. The method set forth in claim 22, wherein the wash solution at the elevated temperature is in the range from about 120*F. to about 200*F.
 24. The method set forth in claim 22, wherein the wash solution in an adjacent one of said zones is at a temperature of about 50*F.
 25. The method set forth in claim 22, wherein the wash solution in the last of said zones is at a temperature of about 190*F.
 26. A method of loosening soil from a mass of randomly arranged, tightly wound, multi-layer rolls of pervious cloth comprising the steps of forming a plurality of cascades of wash solution in a corresponding plurality of zones, transporting the mass of tightly wound rolls through said plurality of zones, while continually draining excess wash solution from the mass of tightly wound rolls from each zone as the mass of tightly wound rolls is transported therethrough, collecting the excess wash solution drained from the mass of tightly wound rolls in each zone and recirculating the collected wash solution to said zone, adding make-up wash solution to each of the plurality of collected drained wash solutions in response to depletion thereof to maintain each of the plurality of cascades of wash solution essentially constant in volume, whereby to maintain the surfaces of the tightly wound rolls wet in each zone for a time sufficient so that upon exiting from the last zone the innermost layers of the tightly wound rolls are saturated thus to loosen the soil from the cloth.
 27. The method set forth in claim 26, wherein the make-up solution added to each of the collected wash solutions is essentially the same as the wash solution to which the make-up solution is added, whereby the character of each of said cascades of wash solution is retained. 